Surface-reacted precipitated calcium carbonate, process to make same, and uses thereof

ABSTRACT

The present invention relates to a process for the preparation of a surface-reacted precipitated calcium carbonate (PCC) pigment having an insoluble, at least partially crystalline calcium salt on its surface. In the process of the present invention, a PCC containing pigment is contacted with H3O+ ions and a solubilized anion in an aqueous medium in the presence of excess solubilized calcium ions to form the surface-reacted PCC having an insoluble, at least partially crystalline calcium salt of the anion formed on its surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional of U.S. application Ser. No. 12/734,992, filed Jul.7, 2010, which is a U.S. National Phase of PCT Application No.PCT/EP2008/066631, filed Dec. 2, 2008, which claims priority to U.S.Provisional Application No. 61/008,208, filed Dec. 19, 2007, andEuropean Application No. 07123077.5, filed Dec. 12, 2007, the contentsof which are hereby incorporated by reference.

The present invention concerns the technical field of high BET specificsurface area mineral fillers based on precipitated calcium carbonate(PCC), which is also known as synthetic calcium carbonate.

Such fillers find applications in a number of domains, including inpaper, namely as a filler or a coating pigment, in tissue paper, inpaints, in plastics, in water treatment, and notably as a means ofremoving pitch and endocrine disrupting compounds (EDC).

The calcium carbonate mineral is generally distinguished according totwo classes: ground (or natural) calcium carbonate (GCC), andprecipitated calcium carbonate (PCC).

GCC is understood to be a naturally occurring form of calcium carbonate,mined from sedimentary rocks such as limestone or chalk, or frommetamorphic marble rocks. GCC is almost exclusively of the calciticpolymorph, which is said to be trigonal-rhombohedral and represents themost stable of the calcium carbonate polymorphs.

By contrast, calcium carbonate polymorphs of the PCC type often include,in addition to calcites, less stable polymorphs of the aragonitic-type,which has an orthorhombic, acicular crystal shape, and hexagonalvateritic-type, which has an even lower stability than aragonite. Thedifferent PCC forms may be identified according to their characteristicx-ray powder diffraction (XRD) peaks.

PCC synthesis most commonly occurs by a synthetic precipitation reactionthat includes a step of contacting carbon dioxide with a solution ofcalcium hydroxide, the latter being most often provided on forming anaqueous suspension of calcium oxide, also known as burnt lime, and thesuspension of which is commonly known as milk of lime. Depending on thereaction conditions, this PCC can appear in various forms, includingboth stable and unstable polymorphs. Indeed, PCC often represents athermodynamically unstable calcium carbonate material.

When referred to in the context of the present invention, PCC shall beunderstood to mean synthetic calcium carbonate products obtained bycarbonation of a slurry of calcium hydroxide, commonly referred to inthe art as a slurry of lime or milk of lime when derived from finelydivided calcium oxide particles in water.

Indeed, it is a significant advantage of the present invention, as willbe understood hereafter, that it implements a PCC obtained by such acommon process. It will, of course, be understood by the skilled manthat further additives, precipitation conditions or steps prior to orfollowing this precipitation may be implemented when forming such PCC bycarbonation of a lime slurry; however, he will immediately recognise theadvantage of being able to implement the process of the presentinvention on any such PCC, including a very basic PCC obtained by simplycarbonating a pure lime slurry.

GCC and PCC forms of calcium carbonate are, on occasion and on anunpredictable basis, observed to present different chemical properties,and frequently it is not possible to use GCC in the same applications asPCC and vice versa.

For example, it was found that the technology described in EP 1 149 136relating to an: “aqueous suspension of one or more pigments, fillers orminerals, which may contain a dispersant polymer to stabilise therheology of the suspension, characterised by the fact that:

a) it contains a natural carbonate and the reaction product or productsof the said carbonate with gaseous CO₂ and the reaction product orproducts of the said carbonate with one or more medium-strong to strongH₃O⁺ ion-providers, and

b) it has a pH greater than 7.5 measured at 20° C.”,

is not transferable to PCC.

It has been found that when implementing PCC in place of GCC (where GCCacts as the “natural carbonate”) in the technology of EP 1 149 136 andnotably when reproducing technology of EP 1 149 136 in the case wherethe CO₂ is generated by continuous addition of the H₃O⁺-ion provider,the specific surface area of the resulting PCC-based product failed todevelop sufficiently.

Indeed, the technology of EP 1 149 136 is of particular interest as itprovides a means of structuring the surface and significantly increasingthe specific surface area of the GCC starting material by controlleddeposition of an at least partially crystalline calcium salt thereon,and such that the calcium source for this deposited material is the GCCmineral itself.

The skilled man, who is eager to obtain such a high surface areamaterial, but wishes to have the option of using a PCC-based startingmaterial, as this material may, for example as a function ofavailability and particular physical properties, present certainadvantages over GCC, is therefore left looking for a solution toimplement the above technology.

In the prior art, it is of note that while a number of documents focuson the introduction of particular additives during the PCC formationprocess, few documents provide any teaching relating to the use of afully formed PCC as an adduct in a process to surface-react this PCC.

U.S. Pat. No. 4,367,207 describes a particular process to prepare PCC.It is stated that care is taken to neutralise any unreacted calciumhydroxide still present in the carbonated slurry, such as by addition ofa sufficient amount of organic or inorganic polybasic acid, namelycitric, maleic, malic, malonic, phthalic, tartaric, boric, phosphoric,sulfurous or sulfuric acid.

WO 2005/123593 relates to a process wherein citric acid is admixed witha calcium hydroxide slurry and the slurry carbonated to produce a slurryof PCC, which is thereafter dewatered to produce a high solids PCCcomposition. It is stated that, optionally, citric acid may be added inconjunction with or subsequent to the addition of a dispersant to theproduced high solids PCC composition, though this option is neitherfurther described nor exemplified. Additionally, it is indicated thatphosphoric acid may be added to the PCC slurry at a given, limitedconcentration never exceeding 0.8% by weight on the weight of PCC, tomaintain the surface area of this PCC.

WO 2005/102931 describes a process wherein a first amount oforganophosphate is added to a calcium hydroxide slurry, prior toaddition of aluminium sulphate and thereafter CO₂ to form a PCC. Asecond amount of organophosphate is then added to the PCC slurry,followed by screening and dewatering of this slurry to form aconcentrated PCC composition. As above, it is indicated that a limitedamount of phosphoric acid never exceeding 1.5% by weight on the weightof PCC, may be admixed with the PCC slurry to stabilise and maintain thePCC surface area.

EP 0 406 662 describes a process for manufacturing a synthetic carbonatein which a pre-mix is made of CaCO₃ in aragonite form with lime: to thisslurry is added a “phosphoric acid derivative” such as phosphoric acidor its salts or various phosphates, and finally CO₂ is introduced inorder to produce conventional carbonation. The purpose of this patent isspecifically to obtain a PCC with a particular acicular crystallineform, of which the industrial manufacture was not previously possible.Phosphoric acid is used in EP 0 406 662 in order to produce specificallythe aragonite form via an unidentified “phosphoric acid calcium” whichprovides new nucleation seeds for the required crystalline form.

It was found by the applicant that the addition of calcium ions via abase (lime) in the process of EP 0 406 662 does not lead to the desiredsurface-reacted PCC.

Indeed, when the Applicant attempted to implement a process wherein thesolubilised calcium ion source was calcium hydroxide as described in EP0 406 662, particularly at the high calcium hydroxide levels describedtherein, the Applicant found that a material was obtained wherein thecalcium forming any at least partially crystalline material at thesurface did not originate from the PCC starting material, but ratherfrom the added calcium hydroxide.

U.S. Pat. No. 5,043,017 describes the acid-stabilisation of calciumcarbonate, and in particular of PCC, by action of a calcium-chelatingagent, such as calcium hexametaphosphate, and a conjugate associatedbase, which can be an alkaline metal salt of a weak acid (phosphoric,citric, boric, acetic, etc.). Indeed, the goal of U.S. Pat. No.5,043,017 is entirely in opposition to the need of the present inventionto maintain the acid-reactivity of the PCC in order to generatesolubilised calcium ions, these ions being needed to form a surfacearea-generating crystal on the PCC surface.

U.S. Pat. No. 4,244,933 describes calcium carbonate particles comprisinga core and projections thereon, prepared by a first step of spraying anaqueous suspension of calcium hydroxide into a reactor from its top incountercurrent relation to the carbon dioxide gas passed upwards throughthe reactor to convert part of the calcium hydroxide to calciumcarbonate, followed by a second step of spraying the resulting mixtureinto another reactor from its top in countercurrent relation to thecarbon dioxide gas passed upwards through the reactor to promotecarbonation of the calcium hydroxide, and a third similar step tocomplete carbonation, wherein the first or second step implementsphosphoric acid and water-soluble salts thereof. These water solublesalts are said to be sodium, potassium, zinc and the like salts ofphosphoric acid.

Finally, whereas EP 1 769 035 discloses a dry mineral pigmentcharacterised in that it contains a product formed in situ by themultiple reaction between a calcium carbonate and:

-   -   the product or products of the reaction of the said carbonate        with one or more moderately strong to strong H₃O⁺ ion donators;    -   the product or products of reaction of the said carbonate with        gaseous CO₂ formed in situ and/or originating from an external        supply;    -   one or more compounds of formula R—X.

However, no further teaching is provided in this document to obtain ahigh specific surface area surface-reacted precipitated calciumcarbonate.

In summary, the prior art:

-   -   focuses largely on the optimisation of the adducts used during        PCC formation, rather than on contacting already formed PCC with        particular additives in order to increase the BET specific        surface area of this PCC;    -   discloses that when PCC is combined with an anion in the form of        a soluble acid or acid salt, and which has an insoluble        corresponding calcium salt, such as phosphoric acid, either no        additional means are referenced to provide the needed        solubilised calcium ions, and this anion only serves to        maintain, and not to significantly develop, the BET specific        surface area of the PCC;    -   discloses that when PCC is combined with an anion in the form of        a soluble acid or acid salt, and which has an insoluble        corresponding calcium salt, such as phosphoric acid, and calcium        ions are provided, these calcium ions are provided in a form        which the Applicant has found do not lead to the desired        surface-reacted PCC.

Entirely by surprise, the Applicant has found that control of particularparameters during such a process as defined hereafter, and notablycontrol of the solubilised calcium ions available at one or morespecific points in this process, is key to the success of forming a highspecific surface area surface-reacted precipitated calcium carbonate.

Namely, the Applicant has developed a process for the preparation of apigment comprising a surface-reacted precipitated calcium carbonate(PCC), the process comprising the following steps:

-   a) providing at least one precipitated calcium carbonate    (PCC)-comprising pigment;-   b) providing H₃O⁺ ions;-   c) providing at least one anion being capable of forming    water-insoluble calcium salts, said anion being solubilised in an    aqueous medium;-   d) contacting said PCC-comprising pigment with said H₃O⁺ ions and    with said solubilised anions in an aqueous medium to form a slurry    of surface-reacted PCC-comprising pigment, wherein said    surface-reacted PCC comprises an insoluble, at least partially    crystalline calcium salt of said anion formed on the surface of at    least part of the PCC provided in step a);

characterised in that an excess of solubilised calcium ions is providedduring Step d).

For the purpose of the present Application, insoluble materials aredefined as those which, when mixed with deionised water and filtered at20° C. to recover the liquid filtrate, provide less than or equal to 0.1g of recovered solid material following evaporation at 95 to 100° C. of100 g of said liquid filtrate. Soluble (or solubilised) materials aredefined as materials leading to the recovery of greater than 0.1 g ofrecovered solid material following evaporation at 95 to 100° C. of 100 gof said liquid filtrate.

For the purpose of the present Application, said excess solubilisedcalcium ions shall correspond to an excess of solubilised calcium ionsrelative to the solubilised calcium ions naturally generated ondissolution of PCC by H₃O⁺ ions, where said H₃O⁺ ions are providedsolely in the form of a counterion to the anion, i.e. via the additionof the anion in the form of an acid or non-calcium acid salt, and inabsence of any further calcium ion or calcium ion generating source.

Said excess solubilised calcium ions provided during step d) arepreferably provided via one or more of the following Routes:

Route IA: addition of a soluble neutral or acid calcium salt;

Route IIA: addition of an acid or a neutral or acid non-calcium saltwhich generates a soluble neutral or acid calcium salt in situ.

Said H₃O⁺ ions may be provided via one or more of the following Routes:

Route IB: addition of acid or an acid salt of said anion;

Route IIB: addition of an acid or an acid salt which simultaneouslyserves to provide all or part of said excess solubilised calcium ions.

For the purpose of the present invention, an “acid” is defined as aBronsted-Lowry acid, that is to say, it is an H₃O⁺ ion-provider. An“acid salt” is defined as an H₃O⁺ ion-provider that is partiallyneutralised by an electropositive element. A “salt” is defined as anelectrically neutral ionic compound formed of anions and cations. A“partially crystalline salt” is defined as a salt that, on XRD analysis,presents an essentially discrete diffraction diagram.

For the purpose of the present invention, a surface-reacted PCC is amaterial comprising PCC and an insoluble, at least partiallycrystalline, calcium salt of said solubilised anion.

In a preferred embodiment, the insoluble calcium salt extends from thesurface of at least part of the PCC.

The calcium ions forming said at least partially crystalline calciumsalt of said anion originate largely from the starting PCC material.

Without wishing to be bound by any theory, the Applicant believes thatin order to form a high specific surface area surface-reacted calciumcarbonate, wherein the calcium ions forming the insoluble, at leastpartially crystalline, calcium salt of said anion are provided largelyby the calcium carbonate starting material, it is necessary not only toliberate these calcium ions from this calcium carbonate, but to do sounder conditions such that said calcium ions are maintained sufficientlymobile to preferentially precipitate, not on the calcium carbonatesurface from which they evolve, but rather on any already formed calciumanion crystals extending from the calcium carbonate surface, such thatsaid crystals grow outward from the carbonate surface and do not coverthe undissolved carbonate before sufficient calcium ions are releasedtherefrom to generate the needed crystal surface to achieve the desiredspecific surface area.

Without wishing to be bound by any theory, the Applicant believes thatPCC synthesised via carbonation of a lime slurry contains unreactedcalcium hydroxide entrapped in the PCC core that migrates to locationsalong the PCC surface. The Applicant theorises that this calciumhydroxide at the PCC surface (or that is brought to the surface if thePCC surface is etched, such as by addition of an acid), forms a layer atthis surface within which an equilibrium is established betweenliberated calcium and hydroxide ions and calcium hydroxide stillassociated with the PCC surface. The Applicant theorises that on simpleaddition of the medium-strong to strong H₃O⁺ ion-provider (hereafterreferred to as acid) via a compound which also serves as the anionsource, as is the most common case in EP 1 149 136 where H₃PO₄ isimplemented, this acid is neutralised on encountering the hydroxide ionsat the PCC surface, and this neutralisation influences the equilibriumin place between the calcium and hydroxide ions and surface-associatedcalcium hydroxide within the mentioned PCC surface layer, such that anexcess of calcium ions are generated at the PCC surface, driving rapidprecipitation of this calcium, not so that outward, surface generatinggrowth of an at least partially crystalline material continues, asdesired, beyond the limits of this surface layer, but rather so that anat least partially crystalline material forms on the PCC surface inimmediate proximity, essentially encompassing this PCC and rendering itunreactive on further acid addition.

The Applicant believes that it is necessary to act against thisphenomenon by acting on the equilibrium in place within said layer tolimit the concentration of free hydroxyl groups therein, which wouldotherwise neutralise the H₃O⁺ ions needed to liberate calcium from PCCand thereby prevent surface area generation. The Applicant has foundthat this may be achieved by increasing the solubilised calcium ionconcentration, namely by providing more solubilised calcium ions thanwould be generated by the acidic or acid salt form of the anion alone.It is of note that these additionally provided solubilised calcium ionsdo not serve to directly form the desired at least partially crystallinematerial so much as they act to ensure that the equilibrium at the PCCsurface is such that needed calcium ions can continue to be obtainedfrom PCC.

The amount of calcium hydroxide present at the PCC surface and thatgenerates the equilibrium layer will vary as a function of the PCCsynthesis conditions. Thus, the amount of additionally providedsolubilised calcium ions has to be adapted, so that specific surfacearea is generated.

Characterisation of Step a): PCC—Comprising Pigment Starting Material

According to Step a) of the process of the present invention, a) atleast one pigment comprising precipitated calcium carbonate (PCC) isprovided.

It is among the merits of the Applicant that he has identified specificreaction condition that allows for the generation of surface area oncontacting a PCC-comprising pigment with an anion and H₃O⁺ ions, via theformation of a calcium crystal, wherein the calcium source isessentially the PCC starting material, ie. the PCC provided in thepigment of step a). Moreoever, the Applicant has identified theconditions such that this process functions when using any form of PCCin the pigment starting material, including calcitic polymorphs such asscalenohedral or rhombohedral calcite, or metastable vaterite andaragonite.

Indeed, the PCC in said PCC-comprising pigment of Step a) may,optionally, be synthesised in the presence of crystal modifiers, such asEDTA or other chelants.

Preferably, upon wet grinding said PCC-comprising pigment under thefollowing conditions, the pH of the wet grinding slurry is observed torise to a greater extent than would be observed upon grinding acorresponding slurry wherein said PCC is entirely replaced with calciticGCC, attesting to the release of unreacted hydroxide from said PCC:

1) replacing the aqueous phase of the slurry with deionised water toform a slurry featuring a solids content, as measured according to themeasurement method provided in the Examples section herebelow, of 15% byweight;

2) grinding the slurry of Step 1) in a grinding chamber using aluminiumoxide grinding beads having a diameter of between 1.0 and 1.6 mm, addedin an amount so as to fill approximately 80% of the volume of thegrinding chamber, and at a grinding speed of 2500 rpm at 24° C. for 180minutes, under a slurry re-circulation rate of 700 ml/minutes.

Namely, the pH, as measured according to the measurement method providedin the Examples section herebelow, is observed to rise by more than 2during this grinding.

In a preferred embodiment, the PCC of said PCC-comprising pigment ofStep a) is hydrophilic, as determined in accordance with the measurementmethod provided in the Examples section herebelow.

In a preferred embodiment, the PCC of said PCC-comprising pigment ofStep a) is issued from a process of involving at least one step ofcomminution. A step of comminution is defined as a mechanical processingstep resulting in the reduction of the original particle size. Suchcomminution steps may, for examples, be performed under conditions suchthat refinement predominantly results from impacts with a secondarybody, ie. in one or more of: a ball mill, a rod mill, a vibrating mill,a roll crusher, a centrifugal impact mill, an attrition mill, a pinmill, a hammer mill, a pulveriser, a shredder, a de-clumper, a knifecutter, or other such equipment known to the skilled man, or may beperformed under conditions such that autogenous grinding takes place.

In a preferred embodiment, the PCC of said PCC-comprising pigment ofStep a) has a weight median diameter of 0.01 to 10 μm, and morepreferably of 0.5 to 2 μm, as measured according to the measurementmethod provided in the Examples section herebelow.

In an optional embodiment, said PCC-comprising pigment of Step a) alsocomprises one or more of the following: talc, clay, plastichollow-sphere pigments or titanium dioxide.

In another embodiment, said PCC-comprising pigment of Step a) consistssolely of PCC.

In a preferred embodiment, said PCC-comprising pigment of Step a) isprovided in the form of an aqueous slurry.

In this preferred embodiment, said slurry preferably has a pH of lessthan 11, preferably of less than 10.5, as measured according to themeasurement method described in the Examples section herebelow, prior toStep c).

In this preferred embodiment, said PCC-comprising pigment is optionallydispersed.

Conventional dispersants known to the skilled person can be used. Thedispersant can be anionic or cationic. A preferred dispersant is onebased on polyacrylic acid. Such dispersants are preferably dosed so asto account for 0.35% by weight of the weight of said PCC-comprisingpigment.

Characterisation of Step b): H₃O⁺ Ion Source

According to Step b) of the process of the present invention, H₃O⁺ ionsare provided. Said H₃O⁺ ions serve to partially dissolve PCC, generatingcalcium ions for subsequent precipitation of an insoluble, at leastpartially crystalline calcium salt of the anion at the PCC surface.

Said H₃O⁺ ions may be provided via one or more of the following Routes:

Route IB: addition of acid or an acid salt of said anion;

Route IIB: addition of an acid or an acid salt which simultaneouslyserves to provide all or part of said excess solubilised calcium ions,ie. by direct addition of soluble calcium ions and/or by dissolution ofthe PCC starting material to liberate calcium ions.

In the case of Route IIB, said acid or acid salt which simultaneouslyserves to provide all or part of said excess solubilised calcium ions ispreferably selected from the group comprising sulphur-comprising acids,such as sulphuric acid, hydrochloric acid, perchloric acid, formic acid,lactic acid, acetic acid, nitric acid, and acid salts thereof, such assoluble calcium acid salts thereof.

Preferably, following the addition of said H₃O⁺ ions to the slurry, thepH of this slurry, as measured according to the measurement method givenin the Examples section herebelow, drops temporarily to a value below6.0.

Characterisation of Step c): Anion Forming the Insoluble Calcium Crystalon PCC

According to Step c) of the process of the present invention, at leastone anion, being capable of forming water-insoluble calcium salts, saidanion being solubilised in an aqueous medium, is provided. Saidinsoluble corresponding calcium salt may, in addition to said anion,include OH— ions and/or crystal water.

Said anion of Step c) may be added in the form of a soluble neutral oracid salt, or in the form of an acid, provided it is solubilised beforeand/or during Step d).

Said anion may be generated by speciation of an additive provided to theprocess. For example, PO₄ ³⁻ and HPO₄ ²⁻ may be generated via additionof H₃PO₄ or a salt of H₂PO₄ ⁻.

Preferably, said anion is selected from one or more of the following:phosphate-comprising anions such as PO₄ ³⁻ and HPO₄ ²⁻, oxalate anions(C₂O₄ ²⁻), carbonate-comprising anions in the form of CO₃ ²⁻,phosphonate anions, succinate anions, or fluoride anions. Morepreferably, said anion is selected from among: phosphate-comprisinganions such as PO₄ ³⁻ and HPO₄ ²⁻, oxalate anions (C₂O₄ ²⁻),carbonate-comprising anions in the form of CO₃ ²⁻, and fluoride anions.Most preferably, said anion is a phosphate-comprising anion such as PO₄³⁻ and HPO₄ ²⁻.

In the embodiment where a carbonate-comprising anion is implemented,said carbonate-comprising anion may be generated in situ via theintroduction of gaseous CO₂ to the slurry. In such a case, the skilledman will know how to implement this introduction in order to favour theconversion of CO₂ to CO₃ ²⁻, such as through the selection of theappropriate temperature.

In a preferred embodiment, said anion is added in a quantitycorresponding to between 5 and 50%, preferably between 15 and 30%, byweight based on the weight of said PCC provided in Step a).

Characterisation of Step d): Contacting the PCC-Comprising Pigment andthe Anion

According to Step d) of the process of the present invention, saidPCC-comprising pigment is contacted, either simultaneously or indistinct steps, with said H₃O⁺ ions and with said solubilised anions inan aqueous slurry environment.

In a preferred embodiment, said anion is contacted with said PCC aftercontacting said PCC with said H₃O⁺ ions.

Moreoever, the process of the present invention is characterised in thatexcess solubilised calcium ions are provided during Step d).

Said excess solubilised calcium ions are preferably provided via one ormore of the following Routes:

Route IA: addition of a soluble neutral or acid calcium salt;

Route IIA: addition of an acid or a neutral or acid non-calcium saltwhich generates a soluble neutral or acid calcium salt in situ.

In the case where said excess solubilised calcium ions are provided viaRoute IA, it may, for example be added as CaCl₂ or Ca(NO₃)₂.

The solubilised calcium ions are preferably provided in a quantitycorresponding to greater than or equal to 3%, preferably greater than orequal to 5%, by weight based on the weight of said PCC provided in Stepa).

In a preferred embodiment, Step d) is carried out at temperatures ofabove 50° C., and preferably of above 60° C.

In a preferred embodiment, Step d) the slurry is mixed so as to developan essentially laminar flow.

In an optional embodiment, Step d) takes place in the presence of atleast one compound selected from the group consisting of silicate,silica, earth alkali metal aluminate, or mixtures thereof.

In this optional embodiment, said silicate is preferably selected froman aluminium silicate, or an earth alkali metal silicate.

In an optional embodiment, Step d) takes place in the presence of aninert gas, which is bubbled through the slurry. One such gas may be CO₂,provided that the when the skilled man implements CO₂ as an inert gas,he adapts the slurry conditions to limit the conversion of this CO₂ to asoluble carbonate.

In an optional embodiment, Step d) takes place in the presence of afurther additive which increases the ionic strength of the slurry, suchas an inert, non-calcium salt. Such salts include, for example, NaCl orKNO₃.

In a preferred embodiment, the aqueous phase of the obtainedsurface-reacted PCC slurry may be replaced with deionised water. In amore preferred embodiment, the aqueous phase of said surface-reacted PCCslurry is collected and recirculated into the process according to thepresent invention as a means to provide all or part of the solubilisedcalcium ions. This is particularly of interest when the processaccording to the invention is a continuous process.

The obtained surface-reacted PCC slurry may be concentrated, optionallyup to the point of obtaining a dry surface-reacted PCC product. In thecase of a dry product, this product may additionally be treated withfatty acids. In the case of a dry product, this product may beadditionally washed with water.

Thus, a slurry of surface-reacted PCC-comprising pigment is obtained,wherein said surface-reacted PCC comprises an insoluble, at leastpartially crystalline calcium salt of said anion, which preferablyextends from the surface of at least part of the PCC of saidPCC-comprising pigment; provided in Step a).

This surface-reacted PCC features a BET specific surface area that isgreater than the BET specific surface area obtained following contactingthe same PCC provided in Step a), either simultaneously or in distinctsteps, with the same solubilised anion of Step b) and with H₃O⁺ ions,such that:

-   -   the H₃O⁺ ions are provided solely via the addition of said        anion, ie. said H₃O⁺ ions are provided in a molar quantity that        is less than or equal to that required to theoretically balance        the ionic charge of said anion; and,    -   neither Route IA nor Route IB are implemented.

In a preferred embodiment, the resulting surface-reacted PCC has a BETspecific surface area that is at least three times, and more preferablyseven times, greater than the BET specific surface area of the PCC inthe PCC-comprising pigment provided in Step a).

Said BET specific surface area and all BET specific surface areasrelating to the present invention are determined in accordance with themeasurement method defined in the Examples section herebelow.

In a preferred embodiment, the obtained slurry comprisingsurface-reacted PCC has a solids content, as measured according to themeasurement method described in the Examples section hereafter, of up to25%, preferably between 5 and 20% by weight.

In a preferred embodiment, a dispersant is added to said slurry.

Preferably, upon wet grinding said surface-reacted PCC-comprisingpigment under the following conditions, the pH of the wet grindingslurry is observed to rise by at least 2 during this wet grindingprocess:

1) replacing the aqueous phase of the slurry with deionised water toform a slurry featuring a solids content, as measured according to themeasurement method provided in the Examples section herebelow, of 15% byweight;

2) grinding the slurry of Step 1) in a grinding chamber using aluminiumoxide grinding beads having a diameter of between 1.0 and 1.6 mm, addedin an amount so as to fill approximately 80% of the volume of thegrinding chamber, and at a grinding speed of 2500 rpm at 24° C. for 180minutes, under a slurry re-circulation rate of 700 ml/minutes.

In a preferred embodiment, said surface-reacted PCC has a calcium saltof the anion:calcium carbonate content mass ratio of 5:95 to 95:5,preferably of 20:80 to 60:40, and more preferably of 25:75 to 50:50, asdetermined according to the TGA measurement described in the Examplessection herebelow.

Said surface-reacted PCC preferably has a pore volume of 1 to 2.2 cm³/g,as determined according to the measurement method provided in theExamples section herebelow.

Said surface-reacted PCC preferably has a BET specific surface area offrom 20 to 120 m²/g, preferably from 55 to 115 m²/g, more preferablyfrom 60 to 100 m²/g, as determined according to the measurement methodprovided in the Examples section herebelow.

Upon XRD analysis of said surface-reacted PCC, according to themeasurement method provided in the Examples section herebelow, said XRDanalysis preferably presents the peaks corresponding to an at leastpartially crystalline calcium of the anion. In a preferred embodiment,said salts include one or more of the following: octacalcium phosphate(OCP), hydroxyapatite (HAP) or tricalcium phosphate (TCP).

Said surface-reacted PCC slurry may be used in paper, tissue paper,plastics, paints, water treatment and to remove EDC compounds.

The following examples illustrate the invention without restricting itsscope.

EXAMPLES

Measurement Methods

The following measurement methods are used to evaluate the parametersgiven in the examples and claims.

Hydrophilicity of a Material

Materials were classified as hydrophilic or not according to thefollowing test. 50 ml of each of the following mixture of water:ethanolare prepared in 100 ml beakers: 100:0, 90:10, 80:20, 70:30, 60:40,50:50, 40:60, 30:70, 20:80, 10:90, 0:100. Thereafter, 0.5 g of thematerial to be tested is passed through a sieve located over the mouthof the beaker (under slight agitation of this sieve to ensure that allof the material passes through it, said sieve openings being sized so asto allow the slowed passage of the material under slight agitation), andallowed to fall freely upon the liquid surface. As of the moment thatsieving is completed, the behaviour of the material at the liquidsurface is observed over a period of 5 minutes to assign a grade to thematerial in each beaker as follows:

0=essentially all of the material sinks within 30 seconds;

0.25=essentially all of the material sinks within 5 minutes;

0.5=more than 50% of the material sinks within 5 minutes;

0.75=more than 25% of the material sinks within 5 minutes;

1=essentially none of the filler sinks within 5 minutes.

The grades assigned are plotted as a function of the water:ethanolratio. Materials were classified as hydrophilic a zero value wasobserved for a water:ethanol mixture of 100:0 to 50:50.

Pore Volume of a Material

Tablets were made from suspensions of the material to be tested. Thetablets are formed by applying a constant pressure to thesuspension/slurry for several hours such that water is released byfiltration through a fine 0.025 μm filter membrane resulting in acompacted tablet of the pigment. The tablets are removed from theapparatus and dried in an oven at 80° C. for 24 hours.

Once dried, single portions from each of the tablet blocks werecharacterised by mercury porosimetry for both porosity and pore sizedistribution using a Micromeritics Autopore IV mercury porosimeter. Themaximum applied pressure of mercury was 414 MPa, equivalent to a Laplacethroat diameter of 0.004 μm (i.e. ˜nm). The mercury intrusionmeasurements were corrected for the compression of mercury, expansion ofthe penetrometer and compressibility of the solid phase of the sample.Further details of the measuring method are described in Transport inPorous Media (2006) 63: 239-259.

Specific Surface Area (SSA) of a Material

The specific surface area is measured via the BET method according toISO 9277 using nitrogen, following conditioning of the sample by heatingat 250° C. for a period of 30 minutes. Prior to such measurements, thesample is filtered, rinsed and dried at 110° C. in an oven for at least12 hours.

Particle Size Distribution (Mass % Particles with a Diameter <X) andWeight Median Grain Diameter (d₅₀) of a Particulate Material

Weight median grain diameter and grain diameter mass distribution of aparticulate material are determined via the sedimentation method, i.e.an analysis of sedimentation behaviour in a gravimetric field. Themeasurement is made with a Sedigraph 5120.

The method and the instrument are known to the skilled person and arecommonly used to determine grain size of fillers and pigments. Themeasurement is carried out in an aqueous solution of 0.1 wt % Na₄P₂O₇.The samples were dispersed using a high speed stirrer and ultrasonic.

X-Ray Diffraction (XRD)

Crystallographic structures of materials were identified based on theXRD analytical technique using Brucker AXS:D8 Advance instrumentation,scanning 2 to 70° 2theta at a scanning speed of 0.5 seconds/step and astep size of 0.01° 2theta. Analysis of the resulting spectra was basedon the PDF 2 database of reference spectra issued by the InternationalCentre for Diffraction Data.

pH of an Aqueous Slurry

The pH of the aqueous suspension is measured using a standard pH-meterat approximately 22° C.

pH Rise on Wet Grinding a Material

The pH rise observed on wet grinding a material is evaluated accordingto the following process:

1) the aqueous phase of the slurry is replaced with deionised water toform a slurry featuring a solids content, as measured according to themeasurement method provided in the Examples section herebelow, of 15% byweight;

2) the slurry of Step 1) is ground in a grinding chamber using aluminiumoxide grinding beads having a diameter of between 1.0 and 1.6 mm, addedin an amount so as to fill approximately 80% of the volume of thegrinding chamber, and at a grinding speed of 2500 rpm at 24° C. for 180minutes, under a slurry re-circulation rate of 700 ml/minutes, andmeasuring the pH over time.

Solids Content of an Aqueous Slurry

The slurry solids content (also known as “dry weight”) is determinedusing a Moisture Analyser HR73 commercialised by Mettler-Toledo with thefollowing settings: temperature of 120° C., automatic switch off 3,standard drying, 5-20 g of slurry.

Calcium Anion Salt:Calcium Carbonate Mass Ratio in a Sample of Material

Calcium anion salt:calcium carbonate mass ratio was evaluated based onthe weight of calcium carbonate in a dried and washed sample ofmaterial, which is determined by thermogravimetric analysis (TGA) usinga Mettler Toledo TGA 851 using a sample of 500+/−50 mg and scanningtemperatures as follows:

-   -   25 to 200° C. at a rate of 20° C./minute;    -   200° C. maintained 15 minutes;    -   200 to 400° C. at a rate of 20° C./minute;    -   400° C. maintained 15 minutes;

under an air flow of 80 ml/min and a nitrogen gas flow of 15 ml/min.This measurement provides a mass of CO₂ gas released from the sample,relative to which a mass of calcium carbonate is calculated. Thedifference between this calculate mass of calcium carbonate and the massof the sample provided corresponds to the mass of calcium anion salt

Preparation of PCC-Comprising Pigments of Step a)

The following is a description of the preparation of the PCC-comprisingpigments of Step a) implemented in subsequent tests described hereafter.

Preparation of a Slurry of Undispersed, Scalenohedral and Calcitic PCC(PCC1)

PCC1 was synthesised by bubbling CO₂ through a slurry of calciumhydroxide so as to obtain a product in slurry featuring the specificsurface area and weight median particle diameter, as determinedaccording to the measurement methods hereabove, given in Table 1, andformed of essentially the scalenohedral morphology of the calcite phaseas determined by XRD analysis. The slurry solids was adjusted to 17% byweight. The pH of this slurry, as measured according to the measurementmethod given above, was between 8 and 9.5.

A sample of this PCC was subsequently wet ground to measure the pHevolution, according to the test method given above. During thisgrinding, the slurry pH was observed to rise by more than 2 and morethan a corresponding slurry wherein the surface-reacted PCC was entirelyreplaced with GCC.

A sample of this PCC was also subjected to the hydrophilicity test givenabove, and determined to be hydrophilic.

Preparation of a Slurry of Dispersed, Scalenohedral and Calcitic PCC(PCC2)

PCC2 was synthesised by bubbling CO₂ through a slurry of calciumhydroxide so as to obtain a product in slurry featuring the specificsurface area and weight median particle diameter, as determinedaccording to the measurement methods hereabove, given in Table 1, andformed of essentially the scalenohedral morphology of the calcite phaseas determined by XRD analysis. The slurry solids was adjusted to 40% byweight in the presence of a polyacrylate-based dispersant. The pH ofthis slurry, as measured according to the measurement method givenabove, was between 8 and 9.5.

A sample of this PCC was subsequently wet ground to measure the pHevolution, according to the test method given above. During thisgrinding, the slurry pH was observed to rise by more than 2 and morethan a corresponding slurry wherein the surface-reacted PCC was entirelyreplaced with GCC.

A sample of this PCC was also subjected to the hydrophilicity test givenabove, and determined to be hydrophilic.

Preparation of a slurry of undispersed, aragonitic PCC (PCC3) PCC3 wassynthesised by bubbling CO₂ through a slurry of calcium hydroxide so asto obtain a product in slurry featuring the specific surface area andweight median particle diameter, as determined according to themeasurement methods hereabove, given in Table 1, and formed ofessentially the aragonitic morphology as determined by XRD analysis.

The slurry solids was adjusted to 17% by weight. The pH of this slurry,as measured according to the measurement method given above, was between8 and 9.5.

A sample of this PCC was subsequently wet ground to measure the pHevolution, according to the test method given above. During thisgrinding, the slurry pH was observed to rise by more than 2 and morethan a corresponding slurry wherein the surface-reacted PCC was entirelyreplaced with GCC.

A sample of this PCC was also subjected to the hydrophilicity test givenabove, and determined to be hydrophilic.

Preparation of a Slurry of Undispersed, Rhombohedral PCC (PCC4)

PCC4 was synthesised by bubbling CO₂ through a slurry of calciumhydroxide so as to obtain a product in slurry featuring the specificsurface area and weight median particle diameter, as determinedaccording to the measurement methods hereabove, given in Table 1, andformed of essentially the rhomobohedral morphology as determined by XRDanalysis. The slurry solids was adjusted to 17% by weight. The pH ofthis slurry, as measured according to the measurement method givenabove, was between 8 and 9.5.

A sample of this PCC was subsequently wet ground to measure the pHevolution, according to the test method given above. During thisgrinding, the slurry pH was observed to rise by more than 2 and morethan a corresponding slurry wherein the surface-reacted PCC was entirelyreplaced with GCC.

A sample of this PCC was also subjected to the hydrophilicity test givenabove, and determined to be hydrophilic.

Example 1

The following Example is illustrative the prior art, and involvescontacting a PCC pigment with H₃O⁺ and a phosphate-comprising anion inthe absence of additional soluble calcium ions.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of the PCC described in theTable herebelow, such that the slurry obtained has a solids content of10% by dry weight. The temperature of this slurry is thereafter broughtto and maintained at 70° C.

Under stirring such that an essentially laminar flow is established,H₃PO₄ in an amount corresponding to 30% by weight on PCC weight and toapproximately 3×10⁻³ moles H₃PO₄ per gram PCC is added to the PCC slurryover a period of 10 minutes. Following this addition, the slurry isstirred for an additional 5 minutes.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is the measured and reported in the Table below.

TABLE 1 Test 1 2 3 4 Prior Prior Prior Prior Art Art Art Art PCC typePPC1 PCC2 PCC3 PCC4 Weight median particle 2.0 1.8 2.7 1.1 diameter (μm)SSA starting material (m²/g) 8 8 6.3 5.5 SSA final product (m²/g) 54 1815 19

Example 2

The following Example is illustrative of the invention, and involvescontacting PCC1 with a phosphate-comprising anion (provided in the formof an acid), in the presence of excess soluble calcium ions, wheresoluble calcium ions are generated on contacting the PCC with an acid oran acid salt having a soluble corresponding calcium salt.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC1 described hereabove,such that the slurry obtained has a solids content of 10% by dry weight.The temperature of this slurry is thereafter brought to and maintainedat a reaction temperature defined in the Table herebelow under“Tslurry”.

Under stirring such that an essentially laminar flow is established, anacid or an acid salt having a soluble corresponding calcium salt(Additive1) in an amount corresponding to a given mole equivalents H₃O⁺ions per gram PCC on contacting the precipitated calcium carbonate(which corresponds to a generation of a given mole equivalents ofsolubilised calcium ions, per gram PCC, both of these given values beinglisted in the Table herebelow), is added to the PCC slurry.

Thereafter, H₃PO₄ in an amount corresponding to 30% by weight on PCCweight and to approximately 3×10⁻³ moles H₃PO₄ per gram PCC is added tothis slurry over a period of 10 minutes. Following this addition, theslurry is stirred for an additional 5 minutes. During this period, thepH of the slurry was observed to decrease temporarily to a value of lessthan 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 1 of Example 1 is also listed in the Table herebelow as areference.

TABLE 2 Test 1 1A 1B 1C 1D Prior Inven- Inven- Inven- Inven- Art tiontion tion tion Tslurry (° C.) 70 70 70 95 70 Additive1 — HCl HCl HClAcetic acid Moles equivalents — 5.5 2.7 5.5 6.6 H₃O⁺ per gram PCC(×10⁻³)** Equivalent moles — 2.7 1.4 2.7 3.3 Ca²⁺ ions per gram PCC(×10⁻³) Equivalent mass Ca²⁺ — 108 54 108 132 ions per gram PCC (×10⁻³)SSA (m²/g) 50 77 88 63 98 **assuming full dissociation of Additive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 3

The following Example is illustrative of the invention, and involvescontacting PCC1 with a phosphate-comprising anion (provided in the formof an acid), in the presence of excess soluble calcium ions, wheresoluble calcium ions are generated on contacting the PCC with an acid oran acid salt having a soluble corresponding calcium salt, and where saidacid or acid salt is dosed at the same time as the phosphate-comprisinganion.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC1 described hereabove,such that the slurry obtained has a solids content of 10% by dry weight.The temperature of this slurry is thereafter brought to and maintainedat a reaction temperature defined in the Table herebelow under“Tslurry”.

Under stirring such that an essentially laminar flow is established, anacid or an acid salt having a soluble corresponding calcium salt(Additive1) in an amount corresponding to a given mole equivalents H₃O⁺ions per gram PCC on contacting the precipitated calcium carbonate(which corresponds to a generation of a given mole equivalents ofsolubilised calcium ions, per gram PCC, both of these given values beinglisted in the Table herebelow), is added to the PCC slurry, whilessimultaneously adding H₃PO₄ in an amount corresponding to 30% by weighton PCC weight and to approximately 3×10⁻³ moles H₃PO₄ per gram PCC isadded to this slurry over a period of 10 minutes. Following thisaddition, the slurry is stirred for an additional 5 minutes. During thisperiod, the pH of the slurry was observed to decrease temporarily to avalue of less than 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 1 of Example 1 is also listed in the Table herebelow as areference.

TABLE 3 Test 1 1E Prior Art Invention Tslurry (° C.) 70 70 Additive1 —H₂SO₄ Moles equivalents H₃O⁺ per gram — 4.0 PCC (×10⁻³)** Equivalentmoles Ca²⁺ ions per — 2.0 gram PCC (×10⁻³) Equivalent mass Ca²⁺ ions per— 80 gram PCC (×10⁻³) SSA (m²/g) 50 115 **assuming full dissociation ofAdditive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 4

The following Example is illustrative of the invention, and involvescontacting PCC1 with a phosphate-comprising anion (provided in the formof an acid), in the presence of excess soluble calcium ions, wheresoluble calcium ions are provided by the addition of a soluble neutralcalcium salt.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC1 described hereabove,such that the slurry obtained has a solids content of 10% by dry weight.The temperature of this slurry is thereafter brought to and maintainedat a reaction temperature defined in the Table herebelow under“Tslurry”.

Under stirring such that an essentially laminar flow is established, asoluble neutral calcium salt (Additive1) in an amount corresponding to agiven mole equivalents Ca²⁺ ions per gram PCC (values being listed inthe Table herebelow), is added to the PCC slurry.

Thereafter, H₃PO₄ in an amount corresponding to 30% by weight on PCCweight and to approximately 3×10⁻³ moles H₃PO₄ per gram PCC is added tothis slurry over a period of 10 minutes. Following this addition, theslurry is stirred for an additional 5 minutes. During this period, thepH of the slurry was observed to decrease temporarily to a value of lessthan 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 1 of Example 1 is also listed in the Table herebelow as areference.

TABLE 4 Test 1 1F 1G Prior Art Invention Invention Tslurry (° C.) 70 7070 Additive1 — CaCl₂ Ca(NO₃)₂ Equivalent moles Ca²⁺ ions per — 1.4 1.2gram PCC (×10⁻³)** Equivalent mass Ca²⁺ ions per — 56 48 gram PCC(×10⁻³) SSA (m²/g) 54 80 90 **assuming full dissociation of Additive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 5

The following Example is illustrative of the invention, and involvescontacting PCC1 with a phosphate-comprising anion (provided in the formof a salt), in the presence of excess soluble calcium ions, where thesoluble calcium ions are generated on contacting the PCC with an acid oran acid salt having a soluble corresponding calcium salt.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC1 described hereabove,such that the slurry obtained has a solids content of 10% by dry weight.The temperature of this slurry is thereafter brought to and maintainedat a reaction temperature defined in the Table herebelow under“Tslurry”.

Under stirring such that an essentially laminar flow is established, anacid or an acid salt having a soluble corresponding calcium salt(Additive1) in an amount corresponding to a given mole equivalents H₃O⁺ions per gram PCC on contacting the precipitated calcium carbonate(which corresponds to a generation of a given mole equivalents ofsolubilised calcium ions, per gram PCC, both of these given values beinglisted in the Table herebelow), is added to the PCC slurry.

Thereafter, Na_((3-x))H_(x)PO₄ where x=0-1 (the value of x beingindicated in the Table below) in an amount corresponding toapproximately 3×10⁻³ moles Na_((3-x))H_(x)PO₄ per gram PCC is added tothis slurry over a period of 10 minutes. Following this addition, theslurry is stirred for an additional 5 minutes. During this period, thepH of the slurry was observed to decrease temporarily to a value of lessthan 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 1 of Example 1 is also listed in the Table herebelow as areference.

TABLE 5 X = 0 X = 1 Test 1 1H 1J Prior Art Invention Invention Tslurry(° C.) 70 70 70 Additive1 — HCl HCl Moles equivalents H₃O⁺ per — 5.5 5.5gram PCC (×10⁻³)** Equivalent moles Ca²⁺ ions — 2.7 2.7 per gram PCC(×10⁻³) Equivalent mass Ca²⁺ ions — 108 108 per gram PCC (×10⁻³) SSA(m²/g) 50 55 108 **assuming full dissociation of Additive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 6

The following Example is illustrative of the invention, and involvescontacting PCC1 or PCC2 with a phosphate-comprising anion (provided inthe form of an acid), in the presence of excess soluble calcium ions,where soluble calcium ions are generated on contacting the PCC with anacid or an acid salt having a soluble corresponding calcium salt, in thepresence of a further additional additive which increases the ionicstrength of the slurry.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC1 or PCC2 describedhereabove, such that the slurry obtained has a solids content of 10% bydry weight. The temperature of this slurry is thereafter brought to andmaintained at a reaction temperature defined in the Table herebelowunder “Tslurry”.

Under stirring such that an essentially laminar flow is established, anacid or an acid salt having a soluble corresponding calcium salt(Additive1) in an amount corresponding to a given mole equivalents H₃O⁺ions per gram PCC on contacting the precipitated calcium carbonate(which corresponds to a generation of a given mole equivalents ofsolubilised calcium ions, per gram PCC, both of these given values beinglisted in the Table herebelow), is added to the PCC slurry.

Under continued stirring, a neutral, soluble salt capable of increasingthe ionic strength of the slurry is added (Additive 2), in an amountlisted in the Table herebelow.

Thereafter, H₃PO₄ in an amount corresponding to 30% by weight on PCC andto approximately 3×10⁻³ moles H₃PO₄ per gram PCC is added to this slurryover a period of 10 minutes. Following this addition, the slurry isstirred for an additional 5 minutes. During this period, the pH of theslurry was observed to decrease temporarily to a value of less than 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 1 of Example 1 is also listed in the Table herebelow as areference.

TABLE 6 PCC1 PCC2 1 1L 1M 2 2A 2B Test Prior Art Invention InventionPrior Art Invention Invention Tslurry 70 70 70 70 70 70 (° C.) Additive1— HCl HCl — HCl HCl Moles — 5.5 5.5 — 5.5 5.5 equivalents H₃O⁺ per gramPCC (×10⁻³)** Equivalent — 2.7 2.7 — 2.7 2.7 moles Ca²⁺ ions per gramPCC (×10⁻³) Equivalent — 108 108 — 108 108 mass Ca²⁺ ions per gram PCC(×10⁻³) Additive2 — NaCl KNO₃ — NaCl KNO₃ % weight — 0.1 0.1 — 0.1 0.1Additive2 on PCC weight SSA (m²/g) 54 61 75 18 48 45 **assuming fulldissociation of Additive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 7

The following Example is illustrative of the invention, and involvescontacting PCC3 with a phosphate-comprising anion (provided in the formof an acid), in the presence of excess soluble calcium ions, wheresoluble calcium ions are generated on contacting the PCC with an acid oran acid salt having a soluble corresponding calcium salt.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC3 described hereabove,such that the slurry obtained has a solids content of 10% by dry weight.The temperature of this slurry is thereafter brought to and maintainedat a reaction temperature defined in the Table herebelow under“Tslurry”.

Under stirring such that an essentially laminar flow is established, anacid or an acid salt having a soluble corresponding calcium salt(Additive1) in an amount corresponding to a given mole equivalents H₃O⁺ions per gram PCC on contacting the precipitated calcium carbonate(which corresponds to a generation of a given mole equivalents ofsolubilised calcium ions, per gram PCC, both of these given values beinglisted in the Table herebelow), is added to the PCC slurry.

Thereafter, H₃PO₄ in an amount corresponding to 30% by weight on PCC andto approximately 3×10⁻³ moles H₃PO₄ per gram PCC is added to this slurryover a period of 10 minutes. Following this addition, the slurry isstirred for an additional 5 minutes. During this period, the pH of theslurry was observed to decrease temporarily to a value of less than 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 2 of Example 1 is also listed in the Table herebelow as areference.

TABLE 7 Test 3 3A Prior Art Invention Tslurry (° C.) 70 70 Additive1 —HCl Moles equivalents H₃O⁺ per — 5.5 gram PCC (×10⁻³)** Equivalent molesCa²⁺ ions — 2.7 per gram PCC (×10⁻³) Equivalent mass Ca²⁺ ions — 108 pergram PCC (×10⁻³) SSA (m²/g) 15 49 **assuming full dissociation ofAdditive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 8

The following Example is illustrative of the invention, and involvescontacting PCC2 with a phosphate-comprising anion (provided in the formof an acid), in the presence of excess soluble calcium ions, wheresoluble calcium ions are generated on contacting the PCC with an acid oran acid salt having a soluble corresponding calcium salt.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC2 described hereabove,such that the slurry obtained has a solids content of 10% by dry weight.The temperature of this slurry is thereafter brought to and maintainedat a reaction temperature defined in the Table herebelow under“Tslurry”.

Under stirring such that an essentially laminar flow is established, anacid or an acid salt having a soluble corresponding calcium salt(Additive1) in an amount corresponding to a given mole equivalents H₃O⁺ions per gram PCC on contacting the precipitated calcium carbonate(which corresponds to a generation of a given mole equivalents ofsolubilised calcium ions, per gram PCC, both of these given values beinglisted in the Table herebelow), is added to the PCC slurry.

Thereafter, H₃PO₄ in an amount corresponding to 30% by weight on PCC andto approximately 3×10⁻³ moles H₃PO₄ per gram PCC is added to this slurryover a period of 10 minutes. Following this addition, the slurry isstirred for an additional 5 minutes. During this period, the pH of theslurry was observed to decrease temporarily to a value of less than 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 2 of Example 1 is also listed in the Table herebelow as areference.

TABLE 8 Test 2 2C Prior Art Invention Tslurry (° C.) 70 70 Additive1 —HCl Moles equivalents H₃O⁺ per — 5.5 gram PCC (×10⁻³)** Equivalent molesCa²⁺ ions — 2.7 per gram PCC (×10⁻³) Equivalent mass Ca²⁺ ions — 108 pergram PCC (×10⁻³) SSA (m²/g) 18 54 **assuming full dissociation ofAdditive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 9

The following Example is illustrative of the invention, and involvescontacting PCC4 with a phosphate-comprising anion (provided in the formof an acid), in the presence of excess soluble calcium ions, wheresoluble calcium ions are generated on contacting the PCC with an acid oran acid salt having a soluble corresponding calcium salt.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC4 described hereabove,such that the slurry obtained has a solids content of 10% by dry weight.The temperature of this slurry is thereafter brought to and maintainedat a reaction temperature defined in the Table herebelow under“Tslurry”.

Under stirring such that an essentially laminar flow is established, anacid or an acid salt having a soluble corresponding calcium salt(Additive1) in an amount corresponding to a given mole equivalents H₃O⁺ions per gram PCC on contacting the precipitated calcium carbonate(which corresponds to a generation of a given mole equivalents ofsolubilised calcium ions, per gram PCC, both of these given values beinglisted in the Table herebelow), is added to the PCC slurry.

Thereafter, H₃PO₄ in an amount corresponding to 30% by weight on PCC andto approximately 3×10⁻³ moles H₃PO₄ per gram PCC is added to this slurryover a period of 10 minutes. Following this addition, the slurry isstirred for an additional 5 minutes. During this period, the pH of theslurry was observed to decrease temporarily to a value of less than 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 2 of Example 1 is also listed in the Table herebelow as areference.

TABLE 9 Test 4 4A Prior Art Invention Tslurry (° C.) 70 70 Additive1 —HCl Moles equivalents H₃O⁺ per — 5.5 gram PCC (×10⁻³)** Equivalent molesCa²⁺ ions — 2.7 per gram PCC (×10⁻³) Equivalent mass Ca²⁺ ions — 108 pergram PCC (×10⁻³) SSA (m²/g) 19 87 **assuming full dissociation ofAdditive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

Example 10

The following Example is illustrative of the invention, and involvescontacting PCC1 with a phosphate-comprising anion (provided in the formof an acid), in the presence of excess soluble calcium ions, wheresoluble calcium ions are generated on contacting the PCC with an acid oran acid salt having a soluble corresponding calcium salt.

In a stainless steel reactor, an aqueous slurry is prepared by adjustingthe solids content of the aqueous slurry of PCC1 described hereabove,such that the slurry obtained features a solids content of 20% by dryweight. The temperature of this slurry is thereafter brought to andmaintained at a reaction temperature defined in the Table herebelowunder “Tslurry”.

Under stirring such that laminar flow is established, an acid or an acidsalt having a soluble corresponding calcium salt (Additive1) in anamount corresponding to a given mole equivalents H₃O⁺ ions per gram PCCon contacting the precipitated calcium carbonate (which corresponds to ageneration of a given mole equivalents of solubilised calcium ions, pergram PCC, both of these given values being listed in the Tableherebelow), is added to the PCC slurry.

Thereafter, H₃PO₄ in an amount corresponding to 30% by weight on PCCweight and to approximately 3×10⁻³ moles H₃PO₄ per gram PCC is added tothis slurry over a period of 10 minutes. Following this addition, theslurry is stirred for an additional 5 minutes. During this period, thepH of the slurry was observed to decrease temporarily to a value of lessthan 6.0.

The final solids of the obtained slurry was between 8 and 12% by weight.

The resulting slurry is allowed to sit overnight before filtering anddrying the obtained product. The final specific surface area of this dryproduct is measured and listed in the Table herebelow.

Test 1 of Example 1 is also listed in the Table herebelow as areference.

TABLE 10 Test Invention Tslurry (° C.) 70 Additive1 HCl Molesequivalents H₃O⁺ per 5.5 gram PCC (×10⁻³)** Equivalent moles Ca²⁺ ions2.7 per gram PCC (×10⁻³) Equivalent mass Ca²⁺ ions 108 per gram PCC(×10⁻³) SSA (m²/g) 88 **assuming full dissociation of Additive1

In all case, when the product obtained according to the process of theinvention was wet ground according to the method provided above, the pHduring wet grinding rose by more than 2 and more than a correspondingslurry wherein the surface-reacted PCC was entirely replaced with GCC.

In all case, when the product obtained according to the process of theinvention was analysed by TGA as described above, a calcium anionsalt:calcium carbonate mass ratio of between 20:80 and 60:40 wasobserved.

XRD analyses of the products obtained according to the process of theinvention indicated the presence of calcium phosphate minerals as wellas calcium carbonate.

1. A surface-reacted precipitated calcium carbonate (PCC) pigment prepared by the process comprising the following steps: a) providing at least one precipitated calcium carbonate (PCC)-comprising pigment; b) providing H3O+ ions; c) providing at least one anion being capable of forming water-insoluble calcium salts, said anion being solubilized in an aqueous medium; d) contacting said PCC-comprising pigment with said H3O⁺ ions and with said solubilized anions in an aqueous medium to form a slurry of surface-reacted PCC-comprising pigment, wherein said surface-reacted PCC comprises an insoluble, at least partially crystalline calcium salt of said anion formed on the surface of at least part of the PCC provided in step a); characterised in that an excess of solubilized calcium ions is provided during step d).
 2. The surface-reacted PCC pigment according to claim 1, which is prepared by the process comprising the following steps: a) providing at least one precipitated calcium carbonate (PCC)-comprising pigment; and b) contacting the PCC-comprising pigment in an aqueous medium with at least one anion that is solubilized in an aqueous medium and forms water-insoluble calcium salts in the presence of excess solubilized calcium ions that are present in the aqueous medium, wherein the anion is in the form of a soluble neutral or acid salt, or is in the form of an acid, wherein the anion is a phosphate-comprising anion, PO₄ ³⁻, HPO₄ ²⁻, an oxalate anion (C₂O₄ ²⁻), a carbonate-comprising anion in the form of CO₃ ²⁻, a phosphonate anion, a succinate anion or a fluoride anion, wherein the anion is added in a quantity corresponding to between 5 and 50% by weight, based on the weight of said PCC provided in step a), and wherein the PCC-comprising pigment in the aqueous medium, the at least one anion, and excess solubilized calcium ions are mixed so as to develop a laminar flow; to form a slurry of surface-reacted PCC comprising an insoluble, at least partially crystalline calcium salt of said anion formed on the surface of at least part of the PCC provided in step a), wherein the excess solubilized calcium ions are provided by the addition to the aqueous medium of: (i) H₃O⁺ ions by addition of an acid or an acid salt that provides all or part of excess solubilized calcium ions in the aqueous medium, wherein the acid or acid salt is a sulphur-comprising acid, sulphuric acid, hydrochloric acid, perchloric acid, formic acid, lactic acid, acetic acid, or nitric acid, or an acid salt thereof, or a soluble calcium acid salt thereof, and/or (ii) a soluble neutral calcium salt that provides all or part of excess solubilized calcium ions in the aqueous medium.
 3. The surface-reacted PCC pigment according to claim 2, wherein the H₃O⁺ ions provide all or part of said excess solubilized calcium ions by dissolution of the PCC to liberate calcium ions.
 4. The surface-reacted PCC pigment according to claim 2, wherein the acid or acid salt that provides all or part of the excess solubilized calcium ions is sulphuric acid, hydrochloric acid, acetic acid, or nitric acid, or an acid salt thereof, or a soluble calcium acid salt thereof.
 5. The surface-reacted PCC pigment according to claim 2, wherein the anion of step b) is a phosphate-comprising anion, PO₄ ³⁻, or HPO₄ ²⁻.
 6. The surface-reacted PCC pigment according to claim 2, wherein the anion of step b) is a carbonate-comprising anion that is generated in situ via the introduction of gaseous CO₂ to the slurry.
 7. The surface-reacted PCC pigment according to claim 2, wherein the anion in step b) is added in a quantity corresponding to between 15 and 30% by weight, based on the weight of said PCC provided in step a).
 8. The surface-reacted PCC pigment according to claim 2, wherein the excess solubilized calcium ions are provided by addition of sulphuric acid, hydrochloric acid or acetic acid.
 9. The surface-reacted PCC pigment according to claim 2, wherein the excess solubilized calcium ions are provided by addition of a soluble neutral calcium salt selected from the group consisting of CaCl₂ and Ca(NO₃)₂.
 10. The surface-reacted PCC pigment according to claim 2, wherein H₃O⁺ ions are provided by addition of hydrochloric acid, and the anion of step b) is a phosphate-comprising anion provided by addition of H₃PO₄.
 11. The surface-reacted PCC pigment according to claim 2, wherein H₃O⁺ ions are provided by addition of acetic acid, and the anion of step b) is a phosphate-comprising anion provided by addition of H₃PO₄.
 12. The surface-reacted PCC pigment according to claim 2, wherein the H₃O⁺ ions are provided by addition of sulphuric acid, and the anion of step b) is a phosphate-comprising anion provided by addition of H₃PO₄.
 13. The surface-reacted PCC pigment according to claim 2, wherein the solubilized calcium ions are provided by addition of CaCl₂, and the anion of step b) is a phosphate-comprising anion provided by addition of H₃PO₄.
 14. The surface-reacted PCC pigment according to claim 2, wherein the solubilized calcium ions are provided by addition of Ca(NO₃)₂, and the anion of step b) is a phosphate-comprising anion provided by addition of H₃PO4.
 15. The surface-reacted PCC pigment according to claim 2, wherein H₃O⁺ ions are provided by addition of hydrochloric acid, and the anion of step b) is a phosphate-comprising anion provided by addition of Na₃PO₄ or Na₄HPO₄.
 16. The surface-reacted PCC pigment according to claim 2, wherein H3O⁺ ions are provided by addition of hydrochloric acid, the anion of step b) is a phosphate-comprising anion provided by addition of H₃PO₄, and step b) takes place in the presence of NaCl.
 17. The surface-reacted PCC pigment according to claim 2, wherein H3O⁺ ions are provided by addition of hydrochloric acid, the anion of step b) is a phosphate-comprising anion provided by addition of H₃PO₄, and step b) takes place in the presence of KNO₃.
 18. The surface-reacted PCC pigment according to claim 2, wherein the surface-reacted PCC so obtained in step b) has a calcium anion salt:calcium carbonate mass ratio of 20:80 to 60:40 as determined by thermogravimetric analysis.
 19. The surface-reacted PCC pigment according to claim 2, which is in the form of a slurry.
 20. The surface-reacted PCC pigment according to claim 2, which is dried to obtain a dry surface-reacted PCC product.
 21. The surface-reacted PCC pigment according to claim 20, wherein the dry surface-reacted PCC product is treated with one or more fatty acids.
 22. The surface-reacted PCC pigment according to claim 2, wherein the salt of the anion extends from the surface of at least part of the surface-reacted PCC pigment.
 23. The surface-reacted PCC pigment according to claim 2, wherein the salt of the anion comprises one or more of octacalcium phosphate (OCP), hydroxyapatite (HAP) and tricalcium phosphate (TCP).
 24. The surface-reacted PCC pigment according to claim 2, having a BET specific surface area that is at least three times greater than the BET specific surface area of the PCC in the PCC-comprising pigment provided in step a).
 25. The surface-reacted PCC pigment according to claim 2, having a BET specific surface area of from 20 to 120 m²/g.
 26. The surface-reacted PCC pigment according to claim 2, a pore volume of 1 to 2.2 cm³/g.
 27. Paper, tissue paper, plastic, paint or water treatment comprising the surface-reacted PCC pigment according to claim 2 in the form of a slurry or a dried surface-reacted PCC. 